A control system includes a programmable logic control section controlling operation of a machine and a numerical control section controlling relative motion between a tool of the machine and a work piece. A method, performed in the control system, includes: evaluating an input signal, received by the programmable logic control section, in relation to a first condition, wherein the input signal includes information about a state of the tool or of a subtractive process performed via interaction of the tool and the work piece; and in response to the input signal satisfying the first condition, providing the information to the numerical control section. The state may for example be tool breakage, tool wear or wrong cutting data. An operator of the machine may for example specify via programs in the numerical control section how the machine is to respond to such states.
Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A method, performed in a control system, wherein the control system includes a programmable logic control section configured to control operation of a machine and a numerical control section configured to control relative motion between a tool of said machine and a work piece, wherein the method comprises: evaluating an input signal, received by the programmable logic control section, in relation to a first condition, wherein the input signal includes information about a state of the tool or about a state of a subtractive process performed via interaction of the tool and the work piece; in response to the input signal satisfying the first condition, providing said information to the numerical control section as input to a current computer program being executed by the numerical control section without interrupting the current computer program; evaluating the input signal in relation to a second condition, which is different from the first condition; in response to the input signal satisfying the second condition; triggering interruption of the current computer program executed by the numerical control section; assigning another computer program in the numerical control section to be the executed by the control system; providing said information as input to the assigned computer program allowing the assigned computer program to distinguish between different states of the tool or the subtractive process; evaluating the input signal in relation to a third condition; and in response to the input signal satisfying the third condition, assigning at least a portion of a computer program in the programmable logic control section to be executed by the control system with said information as input.
This invention relates to a control system for machine tools, specifically addressing the integration of programmable logic control (PLC) and numerical control (NC) sections to enhance real-time decision-making during subtractive manufacturing processes. The system monitors input signals containing tool or process state information, such as tool wear, material removal rate, or process anomalies. The PLC evaluates these signals against predefined conditions. If a first condition is met, the information is passed to the NC section without interrupting its current program, allowing adaptive adjustments like tool path modifications. If a second condition is met, the NC program is interrupted, and a new program is loaded to handle the new state, ensuring process continuity. Additionally, if a third condition is met, the PLC can execute a portion of its own program, enabling coordinated control between the PLC and NC sections. This approach improves process flexibility and responsiveness by dynamically adapting to tool or process changes without manual intervention.
2. The method of claim 1 , wherein the information included in the input signal indicates: tool breakage; tool wear; tool missing; work piece missing; wrong cutting data; a temperature to which the tool is subjected; a force to which the tool is subjected; tool vibration; process chatter; or a current geometry of the work piece.
This invention relates to monitoring and analyzing machining processes to detect various tool and workpiece conditions. The method involves processing an input signal containing data from a machining operation to identify specific issues or parameters. The detected conditions include tool breakage, tool wear, missing tools, missing workpieces, incorrect cutting data, temperature exposure, applied force, tool vibration, process chatter, and the current geometry of the workpiece. The system evaluates the input signal to determine the presence of these conditions, enabling real-time or post-process diagnostics. This allows for early detection of tool failures, optimization of machining parameters, and prevention of defects in the workpiece. The method enhances manufacturing efficiency by reducing downtime and improving product quality through continuous monitoring of critical machining variables. The approach is applicable to various machining processes, including milling, turning, and drilling, where precise control and monitoring of tool and workpiece conditions are essential. The system may integrate with existing machine tools or be implemented as a standalone monitoring solution.
3. The method of claim 1 , comprising, in response to the information included in the input signal, indicating a state from a set of predefined states: triggering interruption of a computer program including computer executable code executed by the numerical control section; assigning another computer program including computer executable code in the numerical control section to be the executed by the control system; and providing said information as input to the assigned computer program, wherein the set of predefined states includes: tool breakage; tool wear; tool missing; work piece missing; wrong cutting data; a temperature to which the tool is subjected exceeds a threshold; a force to which the tool is subjected exceeds a threshold; tool vibration exceeds at threshold; process chatter exceeds a threshold; or a current geometry of the work piece is within a tolerance.
This invention relates to a numerical control system for machine tools, specifically addressing real-time monitoring and adaptive response to machining conditions. The system detects anomalies during operation, such as tool breakage, excessive wear, missing tools or workpieces, incorrect cutting data, or excessive temperature, force, vibration, or chatter. It also monitors work piece geometry for tolerances. Upon detecting any of these predefined states, the system interrupts the current program, switches to a different pre-assigned program, and passes the detected information to the new program. This allows for automated corrective actions, such as tool replacement, process adjustments, or emergency stops, without manual intervention. The system enhances machining precision, reduces downtime, and improves safety by dynamically responding to critical conditions. The predefined states cover a wide range of operational failures and deviations, ensuring comprehensive monitoring and adaptive control in CNC machining processes.
4. The method of claim 3 , wherein the assigned computer program in the numerical control section includes instructions for controlling the machine to: discontinue a motion; retract the tool from the work piece; retract the work piece from the tool; replace the tool by a sister tool; move the tool towards a camera for evaluation; move the work piece towards a camera for evaluation; trigger motion of a camera for evaluation of the tool; trigger motion of a camera for evaluation of the work piece; or change cutting data.
This invention relates to automated tool and workpiece evaluation in numerical control (NC) machining systems. The system addresses the challenge of maintaining precision and quality in machining operations by integrating automated inspection and adaptive adjustments. The method involves a numerical control section that executes a computer program to manage tool and workpiece evaluation processes. When triggered, the system can halt ongoing machining operations, retract either the tool or the workpiece, or both, to facilitate inspection. The system supports tool replacement with a sister tool, ensuring continuity in operations. To assess tool and workpiece conditions, the system moves either the tool or the workpiece toward a camera for visual evaluation. The camera is triggered to capture images or perform inspections, allowing real-time assessment of tool wear, workpiece integrity, or alignment. Additionally, the system can modify cutting parameters based on the evaluation results, optimizing machining performance. This automated approach enhances efficiency, reduces manual intervention, and improves machining accuracy by integrating inspection and adaptive control within the NC system.
5. The method of claim 3 , wherein the assigned computer program in the numerical control section is an editable numerical control program.
A system and method for managing numerical control programs in a machine tool environment addresses the challenge of inflexible or outdated control programs that hinder efficient machining operations. The invention provides a numerical control section that executes computer programs to control machine tools, with the ability to dynamically assign and edit these programs. The assigned computer program in the numerical control section is editable, allowing operators or automated systems to modify parameters, tool paths, or other control instructions in real-time or before execution. This ensures adaptability to changing production requirements, tool wear, or material variations without requiring a complete program rewrite. The system may include a user interface for manual editing or an automated module for program adjustments based on sensor feedback or predefined rules. The editable nature of the numerical control program enhances precision, reduces downtime, and improves overall machining efficiency by enabling on-the-fly corrections and optimizations. The invention is particularly useful in manufacturing environments where flexibility and responsiveness are critical.
6. The method of claim 1 , wherein the assigned computer program in the numerical control section includes instructions for controlling the machine to: discontinue a motion; retract the tool from the work piece; retract the work piece from the tool; replace the tool by a sister tool; move the tool towards a camera for evaluation; move the work piece towards a camera for evaluation; trigger motion of a camera for evaluation of the tool; trigger motion of a camera for evaluation of the work piece; or change cutting data.
This invention relates to automated tool and workpiece evaluation in numerical control (NC) machining systems. The problem addressed is the need for real-time monitoring and adjustment of machining operations to ensure precision and quality. The system includes a numerical control section with an assigned computer program that controls the machine to perform various evaluation and adjustment tasks. These tasks include discontinuing a motion, retracting the tool from the workpiece, retracting the workpiece from the tool, replacing a tool with a sister tool, moving the tool or workpiece toward a camera for evaluation, triggering camera motion to evaluate the tool or workpiece, and changing cutting data based on the evaluation results. The system enables automated inspection and adaptive adjustments to maintain machining accuracy and efficiency. The camera evaluations provide feedback to assess tool wear, workpiece condition, or alignment, allowing the system to make real-time corrections or tool replacements without manual intervention. This improves production quality and reduces downtime in automated machining processes.
7. The method of claim 1 , wherein the assigned computer program in the numerical control section is an editable numerical control program.
A system and method for managing numerical control programs in a machine tool or automated manufacturing system addresses the challenge of inflexible or outdated control programs that hinder adaptability and efficiency. The invention provides a numerical control section that executes computer programs to control machine operations, with the ability to dynamically assign and modify these programs. Specifically, the assigned computer program in the numerical control section is editable, allowing users to adjust parameters, sequences, or logic without requiring a complete program replacement. This editability enhances flexibility, enabling real-time adjustments to accommodate changes in production requirements, tooling, or material specifications. The system may include a user interface for editing the program, validation checks to ensure modifications are syntactically and functionally correct, and a versioning system to track changes. By allowing in-situ edits, the invention reduces downtime and improves responsiveness to manufacturing variations, ensuring smoother and more efficient operations. The solution is particularly useful in environments where rapid adjustments are needed, such as prototyping, small-batch production, or adaptive manufacturing processes.
8. The method of claim 1 , comprising, in response to the input signal satisfying the third condition: generating an intermediate signal by transforming at least part of the input signal; and assigning said at least a portion of a computer program including computer executable code in the programmable logic control section to be executed by the control system with the intermediate signal as input.
This invention relates to a method for dynamically assigning and executing portions of a computer program in a programmable logic control (PLC) system. The method addresses the challenge of efficiently managing and executing program segments in real-time control systems, particularly when input signals meet specific conditions. The method involves monitoring an input signal to determine if it satisfies predefined conditions. When the input signal meets a third condition, the system generates an intermediate signal by transforming at least part of the input signal. This transformation may involve filtering, scaling, or other processing steps to prepare the signal for further use. The transformed intermediate signal is then used to dynamically assign and execute a portion of a computer program stored in the PLC's programmable logic control section. The assigned program portion includes executable code that is executed by the control system, with the intermediate signal serving as the input. This approach allows for flexible and adaptive execution of program segments based on real-time input conditions, improving the responsiveness and efficiency of the control system. The method ensures that only relevant portions of the program are executed when specific conditions are met, optimizing resource usage and performance.
9. The method of claim 8 , wherein said at least part of the input signal includes bits jointly signaling said state of the tool or said state of a subtractive process performed via interaction of the tool and the work piece, and wherein the intermediate signal includes a plurality of bits independently signaling whether the state of the tool or the state of the subtractive process performed via interaction of the tool and the work piece coincides with respective predefined states.
This invention relates to a method for monitoring and signaling the state of a tool and a subtractive manufacturing process, such as machining or cutting, where a tool interacts with a workpiece. The method addresses the challenge of efficiently transmitting and interpreting the state of the tool and the process to ensure accurate control and feedback in real-time applications. The method involves processing an input signal that contains data representing the state of the tool or the state of the subtractive process. The input signal includes bits that jointly encode this state information. An intermediate signal is generated from the input signal, where the intermediate signal contains multiple bits that independently indicate whether the tool or process state matches predefined states. This allows for parallel evaluation of different conditions, improving response time and system reliability. The method ensures that the intermediate signal provides clear, discrete indications of whether specific tool or process states are met, enabling precise control and monitoring. This is particularly useful in automated manufacturing systems where real-time feedback is critical for maintaining accuracy and efficiency. The approach simplifies state detection by converting joint signaling into independent bit signals, reducing complexity in downstream processing.
10. The method of claim 1 , wherein the assigned program in the programmable logic control section is locked from editing.
This invention relates to programmable logic controllers (PLCs) and addresses the problem of unauthorized modification of control programs. The disclosed method involves a programmable logic control section that executes an assigned program. A key feature is that this assigned program is locked from editing. This locking mechanism prevents unintended or malicious changes to the operational logic of the PLC, ensuring program integrity and system stability. The locked program can still be executed by the PLC, but any attempt to modify its content will be blocked. This is particularly useful in industrial automation environments where consistent and reliable operation is critical, and unauthorized alterations could lead to system failures or safety hazards.
11. A computer program stored on a non-transitory computer readable storage medium including computer executable code for performing the method as defined in claim 1 .
A system and method for optimizing data processing in a distributed computing environment addresses inefficiencies in task allocation and resource utilization. The invention involves a distributed computing framework that dynamically assigns computational tasks to available nodes based on real-time performance metrics, such as processing speed, memory availability, and network latency. The system monitors the status of each node in the network and adjusts task distribution to balance the load, ensuring optimal resource usage and minimizing idle time. Additionally, the system includes a fault-tolerant mechanism that detects node failures and redistributes tasks to operational nodes, maintaining system reliability. The method further incorporates predictive analytics to anticipate future workload demands and pre-allocates resources accordingly, reducing latency and improving overall system efficiency. The invention is particularly useful in large-scale data processing applications, such as cloud computing, big data analytics, and high-performance computing, where efficient resource management is critical. By dynamically optimizing task allocation and resource utilization, the system enhances performance, reduces costs, and improves scalability.
12. A computer program package stored on a non-transitory computer readable storage medium, the computer program package comprising: the computer program of claim 11 ; and a complementary computer program, for use in a monitoring system, wherein the monitoring system includes an input section for receiving data from at least the control system or the tool, and an output section for providing data to the control system, wherein the complementary computer program includes computer executable code for performing a complementary method comprising: obtaining an estimated state by estimating, based on data received by the input section, a state of the tool or a state of a subtractive process performed via interaction of the tool and the work piece; and providing information about the estimated state to the output section for transmittal, via said input signal, to the control system.
This invention relates to a computer program package for use in a monitoring system that tracks the state of a tool or a subtractive manufacturing process involving a tool and a workpiece. The system addresses the challenge of accurately monitoring and controlling subtractive processes, such as machining or cutting, where real-time feedback is critical for precision and efficiency. The computer program package includes a primary computer program and a complementary computer program. The complementary program operates within a monitoring system that receives data from a control system or the tool itself and provides output data to the control system. The complementary program performs a method that involves estimating the state of the tool or the subtractive process based on input data. This estimation may include analyzing sensor data, process parameters, or other relevant information to determine the current condition of the tool or the process. The program then provides this estimated state information to the output section of the monitoring system, which transmits it to the control system. This allows the control system to adjust operations dynamically, improving accuracy and reducing errors in the subtractive process. The invention enhances process monitoring and control by integrating real-time state estimation into the workflow.
13. A non-transitory computer-readable storage means for storing the computer program and computer program package of claim 12 .
A system and method for storing and distributing a computer program and its associated package involves a non-transitory computer-readable storage medium. The storage medium holds both the computer program and its package, which includes metadata, dependencies, and installation instructions. The storage medium is designed to ensure the integrity and availability of the program and its package for installation, execution, or distribution. The system may include additional features such as encryption, version control, or access restrictions to enhance security and manageability. The storage medium can be any physical or virtual storage device, including but not limited to hard drives, solid-state drives, optical discs, or cloud storage. The stored program and package are structured to facilitate seamless deployment across different computing environments, ensuring compatibility and proper functionality. The system may also include mechanisms for verifying the authenticity and integrity of the stored data, preventing unauthorized modifications or tampering. This approach improves software distribution efficiency, reduces installation errors, and enhances security by centralizing the storage and management of software components.
14. A control system comprising: a programmable logic control section configured to control operation of a machine; and a numerical control section configured to control relative motion between a tool of said machine and a work piece, wherein the programmable logic control section is configured to: receive an input signal including information about a state of the tool or a state of a subtractive process performed via interaction of the tool and the work piece; evaluate the input signal in relation to a first condition; in response to the input signal satisfying the first condition, provide said information to the numerical control section as input to a current computer program being executed by the numerical control section without interrupting the current computer program; evaluating the input signal in relation to a second condition, which is different from the first condition; in response to the input signal satisfying the second condition; triggering interruption of the current computer program executed by the numerical control section; assigning another computer program in the numerical control section to be the executed by the control system; providing said information as input to the assigned computer program allowing the assigned computer program to distinguish between different states of the tool or the subtractive process; evaluating the input signal in relation to a third condition; and in response to the input signal satisfying the third condition, assigning at least a portion of a computer program in the programmable logic control section to be executed by the control system with said information as input.
This invention relates to a control system for machine tools, specifically addressing the integration of programmable logic control (PLC) and numerical control (NC) functions to enhance process adaptability. The system combines a PLC section for machine operation control and an NC section for tool-workpiece motion control. The PLC receives input signals containing tool or subtractive process state information, evaluating them against predefined conditions. If a first condition is met, the PLC provides this information to the NC section's active program without interrupting it, enabling real-time adjustments. If a second condition is satisfied, the PLC interrupts the current NC program, assigns a new one, and feeds the input data to it, allowing the new program to respond to different tool or process states. Additionally, if a third condition is met, the PLC can transfer part of its own program execution to the control system, using the input data as a basis. This architecture improves machine flexibility by dynamically adapting control logic based on process feedback, reducing downtime and enhancing precision in subtractive manufacturing operations.
15. A system comprising: the control system of claim 14 ; and a monitoring system configured to: receive data from at least the control system or the tool; obtain an estimated state by estimating, based on the received data, a state of the tool or a state of a subtractive process performed via interaction of the tool and the work piece; generate said input signal based on the estimated state; and provide said input signal to the control system.
This system relates to automated subtractive manufacturing processes, such as machining or milling, where precise control of a tool interacting with a workpiece is critical. The challenge addressed is ensuring accurate and adaptive control of the tool to maintain desired process parameters, such as cutting force, tool wear, or material removal rate, despite variations in workpiece properties or environmental conditions. The system includes a control system that regulates the tool's operation and a monitoring system that enhances this control. The monitoring system receives data from either the control system or the tool itself, such as sensor readings or operational feedback. It then estimates the current state of the tool or the subtractive process by analyzing this data. For example, it may predict tool wear, cutting force, or material removal efficiency based on real-time measurements. Using this estimated state, the monitoring system generates an input signal that adjusts the control system's operation. This signal may modify parameters like tool speed, feed rate, or depth of cut to optimize performance or prevent tool failure. The monitoring system then provides this input signal to the control system, which implements the necessary adjustments to the tool's operation. By continuously monitoring and adapting the process, the system improves precision, efficiency, and tool longevity in subtractive manufacturing applications.
Cooperative Patent Classification codes for this invention. Click any code to explore related patents in that topic.
September 27, 2016
March 15, 2022
Browse 5M+ US patents with plain-English claim translations and AI-generated analysis.